Starting control system for synchronous motors



Nov. 21, 1950 w SCHAELCHLIN 2,530,997

STARTING CONTROL SYSTEM FOR SYNCHRONOUS MOTORS Filed llay 28, 19 47 3 Sheets-Sheet 1 P192. I W (W H Field fiequen cg WH'NESSES: INVENTOR & Wa/fer Schae/ch/in.

ATTORN EY Nov. 21, 1950 STARTING CONTROL SYSTEM FOR SYNCHRONOUS MOTORS Filed May 28, 1947 W SCHAELCHLIN 3 Sheets-Sheet 2 WITNESSES:

INVENTOR Wa/ fer .Schae/ch/in.

, BY M- ATTORNEY Nov. 21, 1950 w SCHAELCHLIN sma'rmc comm. sysma FOR syncmzonous uo'roas 3 SheetsSheet 3 Filed May 28, 1947 1 INVENTOR M Wa/fr5chae /ch/in.

Ma. BY

ATTORNEY Patented Nov. 21, 1950' STARTING CONTROL SYSTEM FOR SYNCHBONOUS MOTORS Walter Schaelchlin, Pittsburgh, Pa., assignor to Westinghouse Electric Corporation, East Pittsburgh, Pa.I a corporation of Pennsylvania Application May 28, 1947, Serial No. 751,022

1 Claim. 1

My invention relates to electric systems of control for electric motors, and more particularly to systems for automatically starting-accelerating and synchronizing-synchronous motors.

It is well known and usual practice to start a synchronous motor as an induction motor on the damper windings and at the balancing speed to transfer the motor from induction motor operation to synchronous motor operation. Various automatic control systems are well known to those skilled in the art. with most of such automatic starting control systems, no provision is made to eliminate the undesirable surges occasioned, or produced, in the supply circuit during such transfer, or transition, of the motor from induction motor operation to synchronous motor operation. Furthermore, such transition not only produces the surges mentioned but also produces mechanical shocks to the motor, the load coupled to the motor, and to the generator oi the supply system.

A still more undesirable feature of prior art control systems is that they frequently fail'to synchronize the motor because the pull-in torque that is developed by the motor at the instant the field winding is supplied with direct current may be less than the torque required by the load. The motor thus fails to synchronize even though the normal torque required by the load is less than the maximum torque against which the motor will synchronize if the proper instant were selected for the field excitation. when the field is excited, and no synchronization takes place, the surges and shocks are repeated continually until the overload devices remove the load. In the meantime, the damper winding may be damaged or completely burned out. It is thus apparent that the motor could normally drive the load if the transitionmoment from induction motor operation to synchronous motor operation is so selected, at the balancin speed, that the pole pieces hold the most favorable position with reference to the rotating field in the armature, or primary winding of the motor.

I am also aware that control schemes are known which, with some small measure of success, do select the proper angle between the pole pieces and the rotating flux in the armature windings. Such control schemes are usually expensive and worst of all are not reliable in selecting the most favorable angle. Often such schemes have no power to differentiate beween and proper synchronization then becomes a matter of a one-out-of-two chance. If conditions were right at the moment of transition. all is good and well" if not the machine slips one or more poles before synchronizing. If it does not synchronize, which is more likely to be the case a new trial must be made, still subject to the same chance.

One broad object of my invention, therefore, is to provide for effectively controlling the time of excitation of the field windings with reference to the rotating flux in the stator.

Another object of my invention is the selection of the maximum pull-in torque for synchronization of a synchronous motor.

It is an important and somewhat more specific object of my invention to select a particular point of a particular slip cycle of a synchronous motor for the excitation of the field windings with direct current in such manner as to provide a given polarity on given pairs of alternate poles.

It is also an object of my invention to provide for automatic resynchronization of a synchronous motor after pull-out so as to automatically obtain maximum pull-in torque.

A further object of my invention is the provision of load responsive resynchronizing means for a synchronous motor that dlilerentiate be-" tween the normally heavy starting current and the heavy pull-out current and select only the latter in starting the synchronizing cycle.

It is also an object of my invention to protect the damper winding in case heavy load currents persist preventing normal synchronization or normal resynchronization.

The objects hereinbefore stated are merely illustrative. Many other objects and advantages will become apparent from a study of the following specification and the drawings, in which:

Figure 1 is a diagrammatic showing of an embodiment of my system of control;

Figs. 2 and 2a are diagrammatic showings of the manner in which the field frequency current pulsations vary, near the balancing speed,

in a coil of the field frequency relay embodied in my system of control;

Fig. 3 illustrates a curve showing the voltage variations in the field windings of a synchronous motor as it approaches synchronism;

Figs. 4 and 5 are diagrammatic showings of two modifications of my invention;

Figs. 6 and '7 are diagrammatic showing of two the worst angle and the most iavorable angle ll preferred embodimentsoimy invention; and

Fig. 8 is a portion of a circuit showing a detail.

In Figs. 1, 4 and 5. M designates the synchronous motor of generally conventional design having a field winding 1'' and the usual damper wind- 1118. not shown.

Aline switch 9 is disposed to connect the motor 1! to the alternating-current buses l, 24 and 9. The arrangement of the control is such that the field frequency relay "is operated by means of a main coil l9 before the line switch, or contactor 5 is operated. The instant the line contactor 8 operates, the main coil I3 is deenergized.

Relay i4 is of the inductive time delay type having the closed circuit winding l3 and thus remains in its operated position sufficiently long so that the holding coil 29 becomes energized by the unidirectional pulses of current supplied from the field F through the rectifier 90. The coil 29 is so selected and so connected to the field discharge resistor that its holding effect is a function of the field frequency and the voltage of the field frequency current.

The importance of this function of coil 29 will become more apparent from a study of the operation of my system of control. a

The operation of my system of control as shown in Fig. 1 is as follows:

To start the synchronous motor M, the attendant operates the start push-button 4 whereupon a circuit is established from bus I through the closed contacts 2 of the overload protective device OL, the stop push-button 3, the start pushbutton 4, back contacts 5 of the line contactor 6, the rectifier l, coil H of the frequency relay l4 and conductor 8 to the bus 9.

The energization of the winding l3 of the frequency relay causes the closing of contacts I! and 99 and the opening of contacts 50. The closure of contacts I I causes an energizing circuit to be established from bus I through contacts 2 of the overload device L, stop push-button 3, start push-button 4, conductor l5, contacts I1, conductor l9 actuating coil I! of the lin contactor to the energized conductor 9.

The line contactor 5 is thus operated and effects the closing of contacts 2|, 22, and 23 to connect the motor primary to the buses I, 24, and 9. The instant the motor M is thus supplied with alternating current a current is induced in the field winding F.

The high frequency current in the field discharges through the discharge resistor 26 by a circuit that may be traced from one slip ring of the field F through conductor 25, discharge resistor 28, back contacts 21 on the field contactor 52 and conductor 28 to the other slip ring for the field F. There is thus a definite voltage drop across discharge resistor 26. To energize the field frequency relay with this variable frequency variable voltage field current I connect the main, or holding coil 29 to the resistor 26 through the adjustable lead 3| and the rectifier 90. The coil 29 is thus energized by a current that varies in frequency as indicated by Fig. 2 and varies in voltage with reference to frequency as indicated in Fig. 3.

The operation of the main contactor 8 caused the opening of contacts 5 and the closing of contacts 25. The closing of contacts 20 merely provides a holding circuit for coil l9, but the opening of contacts 5 opens the circuit for coil ll of the field frequency relay 14. Since this relay has an inductive time constant, it will remain picked up long enough for coil 29 to become energized to thus maintain the operated condition 1| cussion in connection with Fig. 1, will suffice.

4 of relay l4. The time constant may be adjusted by screw 94 changing the tension of spring 33.

The operation of relay l4 in closing contacts 99 effects the shunting of coil 91 of the relay l9 energized from the current transformer 99 to thus be normally responsive to surges in the motor armature current. Since coil 31 is shorted by the contacts 29, relay 98 will not operate by the surge of heavy starting current. Contacts 40 thus will b open during normal starting.

The frequency relay I4 is so designed and its characteristics so selected that at some specified low frequency and voltage as point 51 on the voltage curve 59 shown in Fig. 3, the relay l4 will drop out, and in so doing will open contacts 39 and I1, and close contacts 50. The opening of contacts I1 is of no particular significance at this time since the shunting contacts 20 remain closed. The opening of contacts 39 places the relay 99 in operative condition so that this relay will operate as a function of pull-out current surges.

The closing of contacts establishes a circuit from the energized conductor it through contacts 50 and coil 5| of the field contactor 52 to the energized conductor 8. The adjustment and design of the frequency relay and field contactor 52 is such that contacts 54 and 55 close at an instant to obtain maximum pull-in torque. For most motors the field build-up characteristics are such that a closure of contacts 54 and 55 occurs when the alternating current is a point 44. See Fig. 2a. The succeeding positive half cycle 43 will have substantially the relation shown to the current changes as curve 45, that take place in the field F.

The operation of the field contactor as above mentioned establishes a circuit from the positive .terminal through contacts 55, the field F, conductor 28 and contacts 54 to the negative terminal. The design of the field contactor is such that contacts 54 and 55 close an instant before contacts 21 open upon pick-up of contactor 52 and such that contacts 21 close an instant before contacts 54 and 55 open upon drop-out of the field contactor.

In the event of a pull-out of the motor the relay 39 operates to close the contacts 40. The closure of contacts 4!! establishes a circuit from the energized conductor I! through contacts 40, rectifier 1, and coil I! of the frequency relay l4 to the energized conductor 9. The frequency relay I4 picks up thus opening contacts 50. The opening of contacts 50 removes the direct current excitation from the field F, because the deenergization of coil 5| causes the field contactor 52 to drop out.

The motor thus operates as an induction motor with the result that coil 29 is again energized by pulses of unidirectional current from the field F. The shunting of coil 31 by contacts 39 again deenergized coil 31. The result is that resyn chronization again proceeds in the same manner as during the initial starting.

In case of continued excessive loading of the motor, the overload relay 0L, which may be of any convenient design, operates to open contacts 2 to thus effect the stopping of the motor M by the deenergization of the entire control system.

The subject matter shown in Fig." 4 embodies many of the same elements shown in Fig. l, and such elements as are the same are therefore designated by the same reference characters. The operation of the systems shown in Figs. 4 and 5 need not be given in detail since the disrelay I38 has the heating resistor 18 but thisresistorisdeenergisedbyashuntswitch m on relay ll. This is an advantage on pullout since the heating resistor energiaation begins the instant a pull-out occurs and does not have to wait till relay It is operated.

The resynchronizing relay III has another advantage over the relay 8! by providing a time delay during normal starting. At the instant the contacts 2!, I2 and 23 close, there often is a very high transient current. This high transient current, lasting usually no more than one or two cycles, may at times be sumcient in value to cause operation of relay It. Once the relay has operated, the normal load currents may suiilce to hold the armature of this relay in the operated position. Coil it thus remains energized and normal synchronization with minimum pull-in torque may not be obtained With relay It! the thermostatic strip of this relay is not operated immediately no'matter how high the transient current values maybe during the starting cycles. Normal synchronization is thus always eiiected. During resynchronizing' the delay of relay I3! is not needed and may be a slight disadvantage over relay 3.. The choice to be made as between relays It and I depends on the application made, namely the type of load characteristic the motor is called upon to handle.

In Figs. 6 and '7, M designates a conventional synchronous motor having primary windings, the ileld windings and damper windings not shown. The starting contactor means, generally designated by ti, includes the line contactor, suitable push-buttons and overload protective means.

To fully appreciate the contribution to the art I have made. a study of typical operating cycles of my system may be most helpful.

To start the motor M the attendant actuates the start push-button I. This causes the energiaation of the line contactor II by the circuit shown The operation of the line contactor closes the contacts .1, 83. N, l and ll. The closure of contacts 02. a and 84 connects the primary of the motor M to the alternating current buses shown and in consequence the motor starts as an induction motor. The line contactor ll holds itself in through contacts 6! and the closure of contacts It energizes the control circuits.

As the motor M accelerates. the frequency of the alternating current induced in the field F dwiththeriseinmotorspeed. Thisinduced alternating current flows in discharge circuit including the discharge resistor 01 and contests I of the field contactor 1'0.

The drop-out control coil ll of the synchroniaing relay SR is connected in series with the rectifier it across a portion of the discharge resistor 61. The current and frequency in coil ll thus varies as indicated in Fig. 2.

The instant contacts 00 are closed. referring to Fig.1, a circuit is established from the positive terminal ll through contacts 60. back contact I! of the time limit relay T, back contacts II of the field contactor PC, and pick-up coil ll of the synchronizing relay SR to the negative terminal II. This synchronizing relay sR picks up in a relatively short time. In doing so it opens contacts It and closes contacts ll. The opening of contacts II prevents any possible premature operation of the iield contactor FC, whereas the closing of contacts ll establishes a circuit from the positive conductor Ii, contacts 06. actuating coil It of the time limit relay T and contacts 11 to the negative conductor II.

The energisation of coil It causes the opening of contacts I! to thus effect the deenergization of coil 14 of the synchronizing relay-SR. This relay 83 does not drop out because coil II has in the meantime become energized sufficiently to prevent drop out. Contacts ll are also closed but this is merely a set-up operation.

Both the synchronizing relay SR and the time limit relay are of the type shown and described in the R. B. Immel Patent No. 2,406,377 issued on August 2'1, 1946 and entitled "Adjustable Time Limit Device." The synchronizing relay SR, not being provided with a short-circuited windin and, but coupled with a suitable adjustment of the spring means 8. thus has a predetermined relatively short drop-out time, as the time t indicated on Fig. 2.

The time limit relay T is provided with the short-circuited winding It shown and because of this winding and suitable adjustment of the spring means 8' the time constant represents a larger predetermined period than t.

From an inspection of Fig. 2 it will be apparent that the. time period between successive positive half cycles increases as the motor approaches near synchronous speed. From this change it is clear that there will be two half cycles as r and i! having a time period just a trifle less than t but that the time period between 11 and 2 will be greater than t by a relatively small value.

Since coil 10 is energized by the pulsations shown in Fig. 2, it is apparent that the synchronizing relay SR. will always drop out at or near I the beginning of a given positive half cycle, as 2. This synchronizing relay will thus close contacts at a, time represented by point 44. See Fig.

2a. The drop-out of relay SR effects the closing of contacts 8| whereupon a circuit is established from the positive conductor ll through contacts I of the line contactor ll, contacts ll of the time limit relay T, actuating coil 19 of the field contactor PC, and contacts 80 to the negative conductor It.

The field contactor F'C closes an instant after being energized. The selection and design of this contactor is such that it operates in an extremely short time interval. The operation of the field contactor connects, through the closure of contacts II and II, the iield winding 1" to the positive and negative terminals H and 18.

Since the synchronizing relay SR. not only picks the right time. namely, the correct motor but also the right point, as 44, on the induced voltage wave it is apparent that the synchroniza' tion takes place at an instant to provide maximum pull-in torque. The line disturbance is thus a minimum and shocks on the motor and load are avoided. 1

The field contactor holds itself in through contacts 90. The openingof contacts 18 a predetermined time after the opening of contacts 11 thus does not prevent operation of the field contactor.

It will be noted that the connection of the field F to conductors H and 15 also energizes the primary 92 of the transformer TR. The secondary 94 is connected to energize the actuating coil 85 of the resynchronizing relay RSR. During normal synchronous operation the output of the transformer is zero, but in the event of a pullout, large current fluctuations are produced in the transformer primary and in consequence the resynchronizing relay RSR picks up to close the contacts 86. This operation again energizes the coil 14 because contacts 12 are closed during normal synchronous operation.

The resynchronizing relay may be used to shut down the motor M. In this event, the contacts of this relay RSR, as the contacts 86, are disposed directly in series with the contacts of the overload relay 0L controlling the energization of the actuating coil for the line contactor 6|. In the event of a pull-out, the line contactor 6| will thus be deenergized to thus open the contacts 62, 63, and 64. The circuit arrangement mentioned in this paragraph is shown in Fig. 8.

The synchronizing relay operates to open the circuit, at contacts 80, for the field contactor FC. The direct current excitation is thus removed from the field and the coil III of the synchronizing relay SR is again energized by the alternating current induced in the field winding. Synchronization thus takes place in the manner above discussed.

Whether an exciter as E1: is used or not, depends on plant conditions. In some places a constant voltage direct current supply is available, in others not. When not available an exciter must be used. When an exciter is used, there might be diificulty in getting the field contactor FC to operate properly when the exciter is not yet up to field voltage when both contacts 90 that the field contactor operates with the requisite snap even though the exciter voltage is still building up, or while the voltage of the exciter may be fluctuating as it is being loaded with the field F.

After stable synchronous operation is attained, the exciter voltage is also stable and at full value. To prevent the low voltage coil 79' from being injured and yet obtain the required holding force, I utilize a resistor 89 in the holding circuit for coil 19'.

While I have shown and described but one basic embodiment of my invention and two modificaand I8 are closed. The coil 19' is thus so selected 8 tions, I do not wish to be limited to the exact disclosure made but wish to be limited only by the scope or the claim hereto appended.

I claim as my invention:

In a synchronous motor starting control scheme of the type described, the combination of a synchronous motor having an armature winding and a field winding. a plurality of terminal leads normally energized with alternating current, a pair of terminal leads normally energized with direct current, an inductive time limit relay having an armature and adjustable spring means for biasing the armature to the drop-out position by a selected force, a main coil for operating the armature to the pickup position, a line contactor for effecting the connection of the motor armature to the plurality of terminals to thus energize the armature winding with alternating current, means for energizing the said main coil to cause actuation oi the relay armature to its pickup position, means responsive to the operation of the relay armature to the pickup position for effecting the energization of the line contactor, a field contactor for connecting the I field winding to the terminals energized with direct current, said time limit relay having a second coil comprising a holding coil interconnected with the motor field winding, a rectifier and variable impedance in series with the holding coil whereby the time limit relay armature is held in its pickup position by pulses of rectified current having a frequency proportional to the motor slip, control means responsive to the operation of the line contactor for deenergizing the main coil of the inductive time limit relay, a resynchronizing relay interconnected with said synchronous motor to be responsive to relatively high motor armature winding currents, means operable by said inductive time limit relay for making said resynchronizing relay inoperative during starting of the motor, said variable impedance in the circuit of the holding coil being adjusted so that the dropout of the inductive time limit relay occurs at an instant having agiven time relation to a given point on a given fre-' quency cycle, and means responsive to the dropout of the time limit relay for causing the opera tion of the field contactor.

-WALTER SCHAELCHHN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

